Panel wall structure for use in a tower/frame structure and cooling tower

ABSTRACT

A double wall panel member for use in a panel wall is provided which includes a tongue-configured end and a groove-configured end. The panel member includes a first outer wall spaced laterally from a second outer wall, and the groove-configured end has a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, where the first groove wall portion extends further outward than the second groove wall portion. When connected, the wall panel members are assembled with the groove end pointing or oriented upward (not downward) and the tongue end pointing or oriented downward (not upward).

CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY

The present application is a continuation of U.S. patent application Ser. No. 15/444,055 filed on Feb. 27, 2017, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/300,554 filed on Feb. 26, 2016, the disclosures of which are herein incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a panel wall structure for a tower/frame structure and a cooling tower and components for building same.

BACKGROUND

The configuration of the prior art wall panel members and the interconnections they form when assembled have been found to be deficient—allowing water (or other liquids) to leak from interior to exterior of the cooling tower. During installation, conventional prior art wall panel sections are stacked one on top of each other, and the joints are caulked. This prior art connection mechanism is a conventional tongue and groove type connection, with the groove pointing downward and the tongue pointing upward.

Water leaking thru the wall to the exterior has several drawbacks, mainly the undesirable evaporation of the cooling water, as well as creating discoloration of the exterior wall. Accordingly, there exists a need for a new double wall panel structure and interconnections between multiple panels which minimize water or other liquids from leaking through the joints.

SUMMARY

In accordance with one embodiment, there is provided a double wall panel member or structure for use in a wall within a cooling tower. The panel wall member includes a double wall panel member having a first outer wall spaced laterally from a second outer wall, the first and second outer walls comprising fiber reinforced material; a first end having a tongue-type portion extending from the first and second outer walls and having a width narrower than a width of the double wall panel member; and a second end having a groove-type portion and having a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, the first groove wall portion extending further outward than the second groove wall portion.

In accordance with another embodiment, there is provided a panel wall for use with a cooling tower. The panel wall includes a first double wall panel member and a second double wall panel member. Each double wall panel member further includes a first outer wall spaced laterally from a second outer wall, the first and second outer walls comprising fiber reinforced material, a first end having a tongue-type portion extending from the first and second outer walls and having a width narrower than a width of the double wall panel member, and a second end having a groove-type portion and having a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, the first groove wall portion extending further outward than the second groove wall portion. The first end and the second end of the first double wall panel are interconnected to the second end and the first end, respectively, of the second double wall panel.

In accordance with another embodiment, there is provided a cooling tower having a support frame structure defining an interior volume and having at least a first column and a second column; a fluid distribution system to distribute fluid within the interior volume defined by the support frame structure; a heat transfer material within the interior volume defined by the support frame structure and for receiving fluid from the fluid distribution system and through which the fluid travels; a fluid collection basin disposed beneath the support frame structure; air moving equipment operable for causing air movement for heat transfer between the fluid and air; and an exterior panel wall coupled to and spanning between the first column and the second column. The exterior panel wall includes a first double wall panel member and a second double wall panel member. Each double wall panel member has a first outer wall spaced laterally from a second outer wall, a first end having a tongue-type portion extending from the first and second outer walls and having a width narrower than a width of the double wall panel member, and a second end having a groove-type portion and having a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, the first groove wall portion extending further outward than the second groove wall portion. The first end and the second end of the first double wall panel are interconnected to the second end and the first end, respectively, of the second double wall panel, and the second ends are oriented upward and the first ends are oriented downward.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, wherein like numbers designate like objects, and in which:

FIG. 1A illustrates a perspective and partial cross-sectional view of a prior art double wall panel member;

FIG. 1B illustrates a cross-sectional view of a prior art wall panel structure formed using two of the prior art wall panel members shown in FIG. 1A;

FIG. 1C illustrates in more detail a cross-sectional view of the interconnection between the two prior art wall panel members shown in FIG. 1B;

FIGS. 2A and 2B are cross-sectional and perspective views of a wall panel member in accordance with the present disclosure;

FIG. 3 is a more detailed cross-sectional view with dimensional information of the wall panel member shown in FIGS. 2A, 2B in accordance with one embodiment;

FIG. 4 illustrates in more detail a cross-sectional view of an interconnection between two wall panel members shown in FIGS. 2A, 2B and 3;

FIGS. 5A and 5B illustrate two views of a wall panel structure formed of multiple wall panel members for use as an exterior wall in a cooling tower;

FIGS. 6A, 6B and 6C illustrate various views of a cooling tower incorporating the wall panel structure having multiple wall panel members in accordance with the present disclosure; and

FIGS. 7A, 7B and 8A, 8B are detailed cross-sectional views with dimensional information of alternative wall panel members in accordance with other embodiments.

DETAILED DESCRIPTION

Now referring to FIGS. 6A, 6B, and 6C, there is illustrated various views of a cooling tower 600 in accordance with the present disclosure (and which incorporates a number of the wall panel members described in FIGS. 2A-2B, 3 and 4 and herein). It will be understood that the cooling tower 600 and the structures shown throughout the remainder of the figures and described herein represent examples, and the present disclosure is not limited to the structures shown and described.

A cooling tower, generally designated by reference numeral 600 is shown with two cells 632. Each cell 632 is shown as a square about forty-two feet on each side, so its overall footprint is about forty-two by eighty-four feet. Each cell 632 is shown with nine (3×3) bays, with each bay about fourteen by fourteen feet. Other configurations are contemplated, including a single cell or multiple cells, with each cell having any number of bays (e.g., 2×2, 3×3, or uneven combinations). Each cell 632 includes a fan 634 held within a fan shroud 636 that may generally be formed of a fiber reinforced plastic structure that is assembled on top of the cooling tower 600. The fan 634 sits atop a geared fan-speed reducer which itself receives a drive shaft extending from a fan motor. The fan, fan speed reducer and motor may be mounted as conventional in the art, as for example, mounting on a beam such as a steel tube or pipe of appropriately chosen structural characteristics such as bending and shear strength and torsion resistance, or the equipment may be mounted on a beam or joist constructed of fiber-reinforced plastic (FRP). The motor and beam may be located on the roof or top of the cooling tower 600 or within it. In the illustrated embodiment, the fan shroud 636 is mounted on top of a flat deck 638 on top of the cooling tower 600 with a guard rail 640 around the perimeter. A ladder 641 or stairway 643 may also be provided for access to the deck, and walkways may also be provided on the deck.

Beneath the deck 638 are the upper levels 642 (122 in FIG. 1A) of the cooling tower 600 and beneath the upper levels 642 is the bottom or air intake level 644 (120 in FIG. 1A). Beneath the air intake level 644 is a means or mechanism for collecting cooled water from the fill system. In the illustrated embodiment, the collecting means or mechanism is a basin 646, into which cooled water drips and is collected.

The exterior of the upper levels 642 include a casing or panel wall structure 648 that directs the entry of air into the lower levels—so air passes below and upward through the fill material. The panel wall structure 648 is novel and designed to reduce or eliminate water leaking from the interior to the exterior of the cooling tower. The novel panel wall structure in accordance with the present disclosure will be described in further detail below.

As shown in FIG. 6C, the upper levels 642 include a fill level 650 and water distribution level 652. The fill level 650 is below the water distribution level 652, so that water is distributed to drip through the fill level 650 to the collecting basin 646 below. Air is moved through the fill level 650 past the water to cool it. The illustrated fan 634 comprises one possible means for causing air to move through the fill system, although other means or mechanisms may b used, such as a blower n a cross-flow arrangement.

As known in the art, the fill level 650 is filled with fill material 654 that provides a heat transfer function and media. Generally, the fill is open-celled material that allows water to pass downwardly and air to pass upwardly, with heat transfer taking place between the water and air as they pass. Open-celled clay tile or polyvinyl chloride materials or other open cell heat transfer media may be used. Various types of fill material may be used, and such fill material is commercially available. The cooling tower 600 of the present invention is not limited to use of any particular type of fill material. The present invention is also applicable to cross-flow designs.

A water distribution system 649 in the water distribution level 652 above the fill level 650 includes a distribution header 656 that receives hot water from a supply pipe (not shown) that may be connected to the inlet 658 on the exterior of the cooling tower. One distribution header 656 extends across the width of each cell, and each is connected to a plurality of lateral distribution pipes 660 extending perpendicularly from the header 656 to the opposite edges of each cell. The lateral distribution pipes 660 are spaced evenly across each bay, with lateral distribution pipes being provided in each of the fourteen by fourteen foot bays of the illustrated embodiment. Larger or smaller bays may be provided with an appropriate number and spacing of water distribution pipes provided.

Each lateral distribution pipe 660 has a plurality of downwardly directed spray nozzles 663 connected to receive hot water and spray it downward in drops onto the fill material 654, where heat exchange occurs as gravity draws the water drops down to the basin and the fan draws cool air up through the cooling tower. Each lateral distribution pipe may have, for example, ten nozzles, so there may exist eighty nozzles in each bay 662. The water distribution system 649 is shown and described for purposes of illustration only and other designs may also be utilized.

The cooling tower 600 also has a tower/frame structure 100 to support the fan system, water distribution system and fill material, etc., which may be constructed as desired. One example of a tower/frame structure that may be utilized in the cooling tower is described in U.S. Pat. No. 7,275,734 (including FIGS. 1-5 and the accompanying textual description therein), which is incorporated herein by reference.

The tower structure 100 defines an interior volume 665 within which the fill material and substantial portion of the water distribution system are contained. The frame or structure 100 includes a plurality of vertical columns and horizontal beams, and other components.

The cooling tower 600 further includes the collecting basin 646 that defines a base 691 on which the vertical columns 112 are mounted through footings 686. The types of footings and connections available are generally known to those in the art.

As such, the frame/structure 100 includes a plurality of interconnected columns, beams and joists that provide a supporting structure for additional or other components that may be included in the cooling tower 600. Additional components and/or more detailed descriptions of these components in the cooling tower 600 are described in U.S. Pat. No. 5,902,522, which is incorporated herein by reference.

Now referring to FIG. 1A, there is illustrated a prior art wall panel section or member 10 having a double wall design. These sections 10 are connected together to form a prior art exterior panel wall 20 (similar to structure 648 shown in FIG. 6). For illustration purposes only, FIG. 1B illustrates the wall 20 with two sections 10 interconnected together. The sections 10 may be constructed or formed with different dimensions (e.g., length, height and thickness). A typical section 10 may be on the order of 2 to 4 feet in height, 8 to 30 feet in length, and 1-3 inches in thickness—depending on the pultrusion process utilized to manufacture the wall panel sections 10. Referring to FIG. 1C, there is illustrated in more detail a cross-sectional view showing an interconnection between the two prior art wall panel sections 10 shown in FIG. 1B. Though not shown in FIGS. 1A-1C, a typical prior art exterior wall panel 20 will be constructed with a number of individual wall panel sections 10. The number depending on the overall desired dimension of the wall 20.

The configuration of the prior art wall panel members and the interconnections they form when assembled have been found to be deficient—allowing water to leak from interior to exterior of the cooling tower. During installation, each wall panel section 10 is stacked one on top of each other, and the joints are caulked. This prior art connection is a tongue and groove type connection, with the groove pointing downward and the tongue pointing upward.

Water leaking thru the wall to the exterior has several drawbacks, mainly the undesirable evaporation of the cooling water, as well as creating discoloration of the exterior wall.

Now referring to FIGS. 2A and 2B, there are shown cross-sectional and perspective views of a new wall panel member 200 in accordance with the present disclosure. The wall panel member includes a first wall 202 and a second wall 204, with the walls 202, 204 spaced laterally from each other. The thickness may range from about ½ inch to about 4 inches, and other embodiments ranges from 1-2 inches, or is about 1¼ inch. Each wall 202, 204 has an outer surface and an inner surface. One or more inner walls 206 interconnect the first wall 202 and the second wall 204, as shown, to couple the walls 202, 204 together. The ends are configured to interconnect to provide a mechanism to couple two panels 200 together to form the panel wall structure 648 (as shown in FIG. 6C).

The dimensions of the wall panel member 200 may be chosen as desired. FIG. 3 illustrates, in one embodiment, the wall panel member 200 having certain dimensions. Other dimensions are possible. Similar to the prior art wall panel 100, the wall panel members 200 when assembled form a tongue and groove type connection. However, in distinct contrast with the prior art wall panel members, the wall panel members 200 are assembled with the groove end 210 pointing or oriented upward (not downward) and the tongue end 212 pointing or oriented downward (not upward). The specific configurations of the groove end 210 and the tongue end 212 are also shown in FIG. 3.

FIG. 4 illustrates in more detail a cross-sectional view showing an interconnection between two wall panel members 200, in accordance with the present disclosure. It will be appreciated that the groove end 210 includes two extending walls (or flanges) 230, 232 of unequal lengths—as shown. The extending wall 230 extends from the wall 202 while the extending wall 232 extends from the wall 204—as shown. In the embodiment shown, the outer end of the extending wall 232 extends beyond the outer end of the extending wall 230 by a first dimension of about 1¼ inches. As will be appreciated, the first dimension may be longer or shorter, but is preferably between about ½ inch to about 4 inches, and may be about 1 inch or greater. Correspondingly, the tongue end 212 is structured or configured to mate with the configuration of the groove end 210—as shown in more detail in FIG. 4. The ends are complementary. As will be understood, in one embodiment, the end 210 configured with the extending walls 230, 232 extends the entire length of the wall member 200. Similarly, in one embodiment, the end 212 extends the entire length of the wall member 200.

In another embodiment, one of the inner walls 206 a is spaced from the outer end of the extending wall 230 by a second dimension of about ¼ inch. As will be appreciated, the second dimension may be longer or shorter, but is preferably between about ¼ inch to about 2 inches, and may be about 1 inch or less.

The design and structure of panel wall member 200 enables assembly of a wall structure with the groove end upward and tongue end downward—in contrast with how the prior art panel wall members 20 are assembled. In addition, the inventors have determined that this structure and configuration reduces or eliminates the need to caulk the interconnection, unlike the prior art design.

The wall panel member 200 is similarly constructed (as the columns, beams, joists) and may be formed using a pultrusion process. The length of the panel 200 can be any desired length, and is chosen to span between two or more columns of the structure 100, or as needed. In one embodiment, each wall panel member 200 is a single, unitary piece, with lengths ranging from ten to sixty feet, and in one embodiment, is equal to or greater than the column spacing.

According to disclosed embodiments, the panel wall structure 648 may be assembled by interlocking a plurality of wall panel members 200. For example, a plurality of panels 200 may be interlocked to assemble the exterior wall structure 648 having a desired height and/or a desired length. Referring to FIGS. 5A and 5B, there are shown front and side elevation views of the exterior wall structure 648 of the cooling tower 600. As shown, the exterior wall 648 includes a plurality of wall panel members 200 interlocked and stacked on top of each other to form the wall.

It will be understood that the panel wall member 200 described herein is not limited to use in cooling tower structures, but may be used in other structures or installations where it is desirable to contain water or other liquids on one side of the wall.

FIGS. 7A, 7B and 8A, 8B are detailed cross-sectional views with dimensional information of alternative wall panel members 200 b and 200 c, respectively, in accordance with other embodiments. These Figures illustrate, in other embodiments, each of the alternative wall panel members 200 b and 200 c having certain dimensions. Other dimensions are possible.

As shown in FIGS. 7A and 7B, the inner wall 206 b of the groove end 210 b is configured with a slot 700. Correspondingly, the tongue end 212 b is structured or configured to mate with the configuration of the groove end 210 b, and further includes a smaller tongue portion 702 to mate with the slot 700—as shown in FIGURES. The two ends are complementary. As will be understood, in one embodiment, the end 210 b configured with the extending walls 230, 232 and the slot 700 structure extends the entire length of the wall member 200 b. Similarly, in one embodiment, the end 212 b configured with the tongue portion 702 extends the entire length of the wall member 200 b. This tongue-and-groove configuration is hereinafter referred to as a “double tongue-and-groove structure” where the main tongue includes a secondary tongue, while the main groove includes a secondary groove. In other words, the tongue portion includes a main tongue portion and a secondary tongue portion, while the groove portion includes a main groove portion and a secondary groove portion.

As shown in FIGS. 8A and 8B, the inner wall 206 c of the groove end 210 b is configured with a smaller slot 800. Correspondingly, the tongue end 212 c is structured or configured to mate with the configuration of the groove end 210 c, and further includes an even smaller tongue portion 802 to mate with the slot 800—as shown in the FIGURES. The two ends are complementary. As will be understood, in one embodiment, the end 210 c configured with the extending walls 230, 232 and the slot 800 structure extends the entire length of the wall member 200 c. Similarly, in one embodiment, the end 212 c configured with the tongue portion 802 extends the entire length of the wall member 200 c. This configuration is another embodiment of the “double tongue-and-groove structure” where the main tongue includes a secondary tongue, while the main groove includes a secondary groove.

Though not shown in the figures, one or more mechanical means and structures (other than adhesives or other chemicals) may be utilized to securely attach a first double wall panel to a second double wall panel. In other embodiments, no caulking is used in the interconnection joint between the two panels.

It may be advantageous to set forth definitions of certain words and phrases that may be used within this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. The term “couple” or “connect” refers to any direct or indirect connection between two or more components, unless specifically noted that a direct coupling or direct connection is present.

Although the present invention and its advantages have been described in the foregoing detailed description and illustrated in the accompanying drawings, it will be understood by those skilled in the art that the invention is not limited to the embodiment(s) disclosed but is capable of numerous rearrangements, substitutions and modifications without departing from the spirit and scope of the invention as defined by the appended claims. 

What is claimed is:
 1. A panel wall member for use in a wall within a cooling tower, the panel wall member comprising: a double wall panel member having a first outer wall spaced laterally from a second outer wall, the first and second outer walls comprising fiber reinforced material; a first end having a tongue-type portion extending from the first and second outer walls and having a width narrower than a width of the double wall panel member; and a second end having a groove-type portion and having a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, the first groove wall portion extending further outward than the second groove wall portion.
 2. The panel wall member in accordance with claim 1, wherein the first groove wall portion extends at least about one inch further outward than the second groove wall portion.
 3. The panel wall member in accordance with claim 2, wherein the first outer wall and the second outer wall are spaced apart between about ½ inch to about 2 inches.
 4. The panel wall member in accordance with claim 2, wherein the panel wall member is formed of pultruded composite plastic material.
 5. The panel wall member in accordance with claim 1, further comprising: an inner wall member disposed proximate the second end, the inner wall member spanning between and connected to the first outer wall and the second outer wall; and wherein the inner wall member is disposed at a location and configured to abut a surface of a tongue-type portion of a second panel wall member.
 6. The panel wall member in accordance with claim 5, wherein the second groove wall portion extends about 1 inch or less outward from the inner wall member.
 7. The panel wall member in accordance with claim 6, wherein the panel wall member has a length greater than 8 feet and a configuration of the first end and a configuration of the second end extend substantially along the length of the panel wall member.
 8. The panel wall member in accordance with claim 1, further comprising: at least three inner wall members spanning between and connected to the first outer wall and the second outer wall, the at least three inner wall members spaced apart from each other.
 9. The panel wall member in accordance with claim 1, wherein: the first end having the tongue-type portion comprises: a main tongue portion, and a secondary tongue portion; and the second end having the groove-type portion comprises: a main groove portion, and a secondary groove portion.
 10. A panel wall for use with a cooling tower, the panel wall: a first double wall panel member and a second double wall panel member, wherein each double wall panel member comprises: a first outer wall spaced laterally from a second outer wall, the first and second outer walls comprising fiber reinforced material, a first end having a tongue-type portion extending from the first and second outer walls and having a width narrower than a width of the double wall panel member, and a second end having a groove-type portion and having a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, the first groove wall portion extending further outward than the second groove wall portion; and wherein the first end and the second end of the first double wall panel are interconnected to the second end and the first end, respectively, of the second double wall panel.
 11. The panel wall in accordance with claim 10 wherein the second ends are oriented upward and the first ends are oriented downward when the panel wall is attached to a cooling tower.
 12. The panel wall in accordance with claim 10, wherein the first groove wall portion of the double wall panel member extends at least about one inch further outward than the second groove wall portion.
 13. The panel wall in accordance with claim 10, wherein: each double wall panel member further comprises an inner wall member disposed proximate the second end, the inner wall member spanning between and connected to the first outer wall and the second outer wall; and the inner wall member is disposed at a location of each double wall panel member and configured to abut a surface of the tongue-type portion of another double wall member.
 14. The panel wall in accordance with claim 10, wherein the second groove wall portion extends about 1 inch or less outward from the inner wall member.
 15. The panel wall in accordance with claim 14, wherein the panel wall member has a length greater than 8 feet and a configuration of the first end and a configuration of the second end extend substantially along the length of the panel wall member.
 16. The panel wall in accordance with claim 11, wherein each double wall panel member further comprises: at least three inner wall members spanning between and connected to the first outer wall and the second outer wall, the at least three inner wall members spaced apart from each other.
 17. The panel wall in accordance with claim 11, wherein: the first end having the tongue-type portion of each double wall panel member further comprises: a main tongue portion, and a secondary tongue portion; and the second end having the groove-type portion of each double wall panel member further comprises: a main groove portion, and a secondary groove portion.
 18. A cooling tower comprising: a support frame structure defining an interior volume and having at least a first column and a second column; a fluid distribution system to distribute fluid within the interior volume defined by the support frame structure; a heat transfer material within the interior volume defined by the support frame structure and for receiving fluid from the fluid distribution system and through which the fluid travels; a fluid collection basin disposed beneath the support frame structure; air moving equipment operable for causing air movement for heat transfer between the fluid and air; and an exterior panel wall coupled to and spanning between the first column and the second column, the exterior panel wall comprising, a first double wall panel member and a second double wall panel member, wherein each double wall panel member comprises: a first outer wall spaced laterally from a second outer wall, the first and second outer walls comprising fiber reinforced material; a first end having a tongue-type portion extending from the first and second outer walls and having a width narrower than a width of the double wall panel member; and a second end having a groove-type portion and having a first groove wall portion extending from the first outer wall and a second groove wall portion extending from the second outer wall, the first groove wall portion extending further outward than the second groove wall portion, wherein the first end and the second end of the first double wall panel are interconnected to the second end and the first end, respectively, of the second double wall panel, and wherein the second ends are oriented upward and the first ends are oriented downward.
 19. The cooling tower in accordance with claim 18, wherein the first groove wall portion of each double wall panel member extends at least about one inch further outward than the second groove wall portion.
 20. The cooling tower in accordance with claim 18, wherein: each double wall panel member further comprises an inner wall member disposed proximate the second end, the inner wall member spanning between and connected to the first outer wall and the second outer wall; and the inner wall member is disposed at a location of each double wall panel member and configured to abut a surface of the tongue-type portion of another double wall member. 